Kohler 12RESL Operation Manual Download Page 43

TP-6517 1/11

Appendix 43

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp

ampere

ABDC

after bottom dead center

AC

alternating current

A/D

analog to digital

ADC

advanced digital control;
analog to digital converter

adj.

adjust, adjustment

ADV

advertising dimensional
drawing

Ah

amp-hour

AHWT

anticipatory high water
temperature

AISI

American Iron and Steel
Institute

ALOP

anticipatory low oil pressure

alt.

alternator

Al

aluminum

ANSI

American National Standards
Institute (formerly American
Standards Association, ASA)

AO

anticipatory only

APDC

Air Pollution Control District

API

American Petroleum Institute

approx.

approximate, approximately

AQMD

Air Quality Management District

AR

as required, as requested

AS

as supplied, as stated, as
suggested

ASE

American Society of Engineers

ASME

American Society of
Mechanical Engineers

assy.

assembly

ASTM

American Society for Testing
Materials

ATDC

after top dead center

ATS

automatic transfer switch

auto.

automatic

aux.

auxiliary

avg.

average

AVR

automatic voltage regulator

AWG

American Wire Gauge

AWM

appliance wiring material

bat.

battery

BBDC

before bottom dead center

BC

battery charger, battery
charging

BCA

battery charging alternator

BCI

Battery Council International

BDC

before dead center

BHP

brake horsepower

blk.

black (paint color), block
(engine)

blk. htr.

block heater

BMEP

brake mean effective pressure

bps

bits per second

br.

brass

BTDC

before top dead center

Btu

British thermal unit

Btu/min.

British thermal units per minute

C

Celsius, centigrade

cal.

calorie

CAN

controller area network

CARB

California Air Resources Board

CB

circuit breaker

cc

cubic centimeter

CCA

cold cranking amps

ccw.

counterclockwise

CEC

Canadian Electrical Code

cert.

certificate, certification, certified

cfh

cubic feet per hour

cfm

cubic feet per minute

CG

center of gravity

CID

cubic inch displacement

CL

centerline

cm

centimeter

CMOS

complementary metal oxide
substrate (semiconductor)

cogen.

cogeneration

com

communications (port)

coml

commercial

Coml/Rec Commercial/Recreational
conn.

connection

cont.

continued

CPVC

chlorinated polyvinyl chloride

crit.

critical

CRT

cathode ray tube

CSA

Canadian Standards
Association

CT

current transformer

Cu

copper

cUL

Canadian Underwriter’s
Laboratories

CUL

Canadian Underwriter’s
Laboratories

cu. in.

cubic inch

cw.

clockwise

CWC

city water-cooled

cyl.

cylinder

D/A

digital to analog

DAC

digital to analog converter

dB

decibel

dB(A)

decibel (A weighted)

DC

direct current

DCR

direct current resistance

deg.,

°

degree

dept.

department

DFMEA

Design Failure Mode and
Effects Analysis

dia.

diameter

DI/EO

dual inlet/end outlet

DIN

Deutsches Institut fur Normung
e. V. (also Deutsche Industrie
Normenausschuss)

DIP

dual inline package

DPDT

double-pole, double-throw

DPST

double-pole, single-throw

DS

disconnect switch

DVR

digital voltage regulator

E, emer.

emergency (power source)

ECM

electronic control module,
engine control module

EDI

electronic data interchange

EFR

emergency frequency relay

e.g.

for example (

exempli gratia)

EG

electronic governor

EGSA

Electrical Generating Systems
Association

EIA

Electronic Industries
Association

EI/EO

end inlet/end outlet

EMI

electromagnetic interference

emiss.

emission

eng.

engine

EPA

Environmental Protection
Agency

EPS

emergency power system

ER

emergency relay

ES

engineering special,
engineered special

ESD

electrostatic discharge

est.

estimated

E-Stop

emergency stop

etc.

et cetera (and so forth)

exh.

exhaust

ext.

external

F

Fahrenheit, female

fglass.

fiberglass

FHM

flat head machine (screw)

fl. oz.

fluid ounce

flex.

flexible

freq.

frequency

FS

full scale

ft.

foot, feet

ft. lb.

foot pounds (torque)

ft./min.

feet per minute

ftp

file transfer protocol

g

gram

ga.

gauge (meters, wire size)

gal.

gallon

gen.

generator

genset

generator set

GFI

ground fault interrupter

GND,

ground

gov.

governor

gph

gallons per hour

gpm

gallons per minute

gr.

grade, gross

GRD

equipment ground

gr. wt.

gross weight

H x W x D height by width by depth
HC

hex cap

HCHT

high cylinder head temperature

HD

heavy duty

HET

high exhaust temp., high
engine temp.

hex

hexagon

Hg

mercury (element)

HH

hex head

HHC

hex head cap

HP

horsepower

hr.

hour

HS

heat shrink

hsg.

housing

HVAC

heating, ventilation, and air
conditioning

HWT

high water temperature

Hz

hertz (cycles per second)

IC

integrated circuit

ID

inside diameter, identification

IEC

International Electrotechnical
Commission

IEEE

Institute of Electrical and
Electronics Engineers

IMS

improved motor starting

in.

inch

in. H

2

O

inches of water

in. Hg

inches of mercury

in. lb.

inch pounds

Inc.

incorporated

ind.

industrial

int.

internal

int./ext.

internal/external

I/O

input/output

IP

iron pipe

ISO

International Organization for
Standardization

J

joule

JIS

Japanese Industry Standard

Summary of Contents for 12RESL

Page 1: ...Residential Commercial Generator Sets Models 12RESM1 12 18RESL Controller DC RET Digital Control TP 6517 1 11d Operation...

Page 2: ...eadily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set...

Page 3: ...r Set 16 2 4 2 Stopping Generator Set 17 2 5 Exercising Generator Set 17 2 6 Faults 17 2 6 1 Shutdowns 17 2 6 2 Warnings 17 2 6 3 Resetting Controller after a Fault Shutdown 17 2 7 Battery Charger 19...

Page 4: ...e Oil Recommendation 33 4 3 4 Oil Change Procedure 33 4 3 5 Oil Cooler 34 4 4 Spark Plugs 34 4 5 Air Cleaner Service 35 4 6 Cooling System 35 4 7 Exhaust System 36 4 8 Battery 36 4 9 Battery Charger 3...

Page 5: ...r set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables n...

Page 6: ...tainer when removing the fuel line or carburetor Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these mater...

Page 7: ...set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances w...

Page 8: ...NING Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Notice NOTICE...

Page 9: ...he prescribed intervals Obtain service from an authorized service distributor dealer to keep equipment in top condition Nameplate The following illustration shows a typical generator set nameplate Cop...

Page 10: ...eadquarters Europe Middle East Africa EMEA Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Offic...

Page 11: ...sign and full pressure lubrication for maximum power torque and reliability under all operating conditions D Dependable maintenance free electronic ignition D Precision formulated cast iron constructi...

Page 12: ...eld connection terminal block location 11 Spark plug locations both sides 12 Oil drain hose 13 Oil drain valve 14 Oil filter 15 Exhaust 16 Equipment ground 17 Battery charger 18 DSAI lead location 19...

Page 13: ...2 RS 232 connector for application program updates 13 Engine starting battery location battery purchased separately 14 Oil drain hose 15 Nameplate location on base 16 Oil drain valve 17 Exhaust outlet...

Page 14: ...TP 6517 1 11 14 Section 1 Features Notes...

Page 15: ...ct the exhaust system components for cracks leaks and corrosion D Check for corroded or broken metal parts and replace them as needed D Check that the exhaust outlet is unobstructed Oil Level Maintain...

Page 16: ...dark and battery draw is minimized A remote start signal from a transfer switch or a remote start stop switch connected to controller leads 3 and 4 reactivates the controller Moving the generator set...

Page 17: ...y items restricting the air flow 2 6 Faults 2 6 1 Shutdowns Under the fault shutdown conditions listed in Figure 2 3 the generator set shuts down automatically and the controller displays a fault code...

Page 18: ...is sensed during cranking Shuts down 3 seconds after the fault is detected OF Overfrequency shutdown Shutdown occurs when the governed frequency exceeds 110 of the system s frequency setpoint for mor...

Page 19: ...process Figure 2 5 Charging Method Display Operating Condition Red ON Green OFF When the red LED is on it indicates the battery is discharged and the battery charger is recharging at the BULK rate st...

Page 20: ...TP 6517 1 11 20 Section 2 Operation Notes...

Page 21: ...evere injury or death Do not work on the generator set until it cools WARNING Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhau...

Page 22: ...m Tighten control and power wiring connections X Yearly Remote control system if equipped X Monthly Visible wear or damage X Quarterly Wire abrasions where subject to motion X X Six Months Wire cable...

Page 23: ...dation Use API American Petroleum Institute Service Class SG SH or SJ synthetic oil Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner Sel...

Page 24: ...heck the oil level Add oil to bring the level up to the F mark on the dipstick 4 Check for leaks a Check for oil leaks b Fix leaks and recheck the oil level c Reinstall the housing side panel 3 3 5 Oi...

Page 25: ...e Figure 3 4 and Figure 3 5 1 514 Figure 3 4 Checking the Spark Plug Gap 1 511 Figure 3 5 Adjusting the Spark Plug Gap 3 5 Air Cleaner Element and Precleaner The engine has a replaceable high density...

Page 26: ...ning knob and remove the cover 5 Remove the element cover nut element cover and the paper element with precleaner 6 Remove the precleaner from the paper element Note Do not wash the paper element or c...

Page 27: ...has ceased Flush the resulting liquid with water and dry the area Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks...

Page 28: ...T 115 VAC 50 60Hz 1 6A OUTPUT 12 VDC 6 Amps MAX BAT 180 Amp Hr Max DATE 6 AMP AUTOMATIC BATTERY CHARGER R C US LISTED BATTERY CHARGER 53AB 2608KH 1 1 LED indicators 2 Mounting flanges 3 AC power cord...

Page 29: ...ator set master switch in the OFF RESET position 3 11 3 Cylinder Lubrication 1 Remove the spark plugs 2 Pour one tablespoon of engine oil into each spark plug hole Install the spark plugs and ground t...

Page 30: ...TP 6517 1 11 30 Section 3 Scheduled Maintenance 12 kW Models Notes...

Page 31: ...ator set until it cools WARNING Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot duri...

Page 32: ...mote control system if equipped M Visible wear or damage Q Wire abrasions where subject to motion 6 months 6 months Wire cable insulation condition 3Y or 500 Engine and Mounting Visible wear or damage...

Page 33: ...Oil Check 4 3 3 Engine Oil Recommendation Use 5W 30 API American Petroleum Institute Service Class SG SH or SJ synthetic oil Synthetic oil oxidizes and thickens less than other oils and leaves the en...

Page 34: ...bris See Figure 4 2 for the oil cooler location The oil cooler is located under the No 2 cylinder shroud Remove the top mounting screw and loosen the two side screws then lift off the cylinder shroud...

Page 35: ...nt or damaged 4 When servicing the air cleaner check the air cleaner base and latch Make sure it is secured and not bent or damaged Also check the element cover for damage or improper fit Replace all...

Page 36: ...Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns...

Page 37: ...RY CHARGER 53AB 2608KH 1 1 LED indicators 2 Mounting flanges 3 AC power cord 2 5 2 3 4 4 Fuse 5 Battery leads 12 VDC Figure 4 8 6 Amp Float Equalize Battery Charger 4 10 Circuit Protection If the gene...

Page 38: ...ne stops 4 Place the generator set master switch in the OFF RESET position 4 11 3 Cylinder Lubrication 1 Remove the spark plugs 2 Pour one tablespoon of engine oil into each spark plug hole Install th...

Page 39: ...ection 2 6 If a fault code is displayed identify and correct the cause of the fault condition Then reset the controller See Section 2 6 3 Problem Possible Cause Corrective Action Controller LED displa...

Page 40: ...re insufficient Check the fuel supply and valves Engine malfunction Contact the distributor dealer No AC output AC circuit breaker in the OFF position Place the circuit breaker in the ON position AC c...

Page 41: ...off all DC equipment while charging Red and green LEDs stay on for more than 24 hours Onboard DC systems are drawing between 1 5 and 5 amps Turn off all DC equipment while charging One or more inopera...

Page 42: ...TP 6517 1 11 42 Section 5 Troubleshooting Notes...

Page 43: ...ter s Laboratories CUL Canadian Underwriter s Laboratories cu in cubic inch cw clockwise CWC city water cooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dB A decibe...

Page 44: ...ersize overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz ounce p pp page pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph phase PHC Phi...

Page 45: ...Notes...

Page 46: ...Notes...

Page 47: ......

Page 48: ...CO Kohler Wisconsin 53044 Phone 920 457 4441 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPower com Kohler Power Systems Asia Pacific Headquart...

Reviews: